Method for applying heat bondable lamina to a substrate

ABSTRACT

Apparatus and method suitable for making a plurality of laminated substrates by applying a plurality of laminate sheets to corresponding plurality of substrates. The apparatus includes a lamina supply member capable of holding a supply of lamina from which successive sheets of lamina can be cut. A cutter is disposed in the apparatus such that the cutter is capable of cutting through the lamina to provide said successive sheets of laminate. A heater is provided for bonding each successive sheet of laminate to a corresponding substrate whereby the corresponding laminated substrate is formed. The supply of lamina is characterized by a current leading edge. The supply of lamina is cut through along a cutting line at a predetermined distance from the current leading edge of the lamina. This provides a first sheet of laminate having a trailing edge at the cutting line. Cutting also provides the lamina supply with a successive leading edge at the cutting line. There is substantially no wasted lamina material between the trailing edge of the laminate sheet and the successive leading edge of the lamina. The laminate sheet is then bonded to a corresponding substrate. The steps of cutting the lamina along a cutting line and bonding the resultant lamina sheet to a corresponding substrate are repeated a plurality of times to yield the plurality of laminated substrates.

This is a division of application Ser. No. 08/630,681, filed Apr. 12,1996, now U.S. Pat. No. 5,783,024.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for makinglaminated cards. More particularly, the present invention relates to amethod and apparatus for laminating a plurality of heat bondablelaminate sheets to a corresponding plurality of card substrates.

BACKGROUND OF THE INVENTION

Laminated cards are widely used as certificates of citizenship, employeeidentification cards, passports, driver's licenses, transaction cards,and other applications of a similar nature in which such cards establisha person's authorization to conduct certain activities. Laminated cardstypically comprise a card-shaped substrate made from a suitable materialsuch as paper, cardboard, or plastic. Information such as photographs,data, textual information, graphics, or the like, may be printed on oneor both sides of the cards. In some applications, information may alsobe optically or magnetically stored on recording media provided withinor on the surfaces of such cards.

In view of the widespread use of laminated cards, it is important thatthe information provided with the cards be protected against damage. Itis also important that the information be protected against unauthorizedalterations. Accordingly, the information provided on the substrate maybe covered by a protective plastic laminate sheet which is bonded to thesubstrate. Most commonly, heat-activated adhesives are used toaccomplish such bonding.

When printed information on the substrate is protected by a plasticlaminate sheet, the plastic sheet would have to be removed from thesubstrate in order to alter the printed information and thensubsequently replaced after the alteration has been completed. Toprotect against this activity, the plastic sheet may include anauthentication image of a type which is destroyed when the plastic filmis removed, such as a holographic image, ultraviolet image, an imageformed with pearlescent ink, a chemical patch, and the like. In analternative approach, the authentication image is substantiallyinvisible until the plastic is removed, after which the image becomespermanently visible. In either approach, the change in the state of theimage indicates that the plastic film has been removed from thesubstrate. This, in turn, suggests that the printed information on thesubstrate may have been altered.

A number of different approaches have been used to laminate heatbondable plastic laminate sheets to card substrates, but such approacheswhich have been used for manufacturing large quantities of laminatedcards tend to generate a substantial amount of waste material. Forexample, according to a "decal" approach, a 2 to 3 micron thick, heattransferrable, plastic laminate material is supported upon a carrierweb. To apply the laminate material to the substrate, the substrate andthe laminate material are brought into contact, and then the laminatematerial is transferred to the card using heat. This approach does notwork too well, because the 2 to 3 micron thick coating is too thin toadequately protect the card against scratches and ultraviolet bleaching.Additionally, the left-over carrier web becomes scrap which must bethrown away. Additionally, left-over, and hence wasted, laminatematerial remains on the carrier web in between the transferred areas.

According to a "die-cut" approach, a much thicker laminate material issupported upon a carrier web. with the laminate material being supportedupon the carrier web, a plurality of individual, spaced-apart laminatesheets are die-cut in the laminate material in a manner such that thecarrier web itself is not cut at all, or at least is not cut entirelythrough. After die-cutting, the excess laminate material between thespaced-apart sheets is removed from the web and thrown away as scrap,thus leaving only the spaced apart, die cut sheets on the web. Theindividual sheets must be spaced apart relative to each other when usingthis approach in order to allow registration marks to be placed on thematerial in the unused regions between the sheets. The registrationmarks are used to register the sheets on corresponding substrates. Eachsuccessive die-cut sheet is then bonded to a corresponding substrateusing a heater. The individual sheets must also be spaced apart in orderto allow the carrier web to be pulled away from the heater after bondingin order to bring the next sheet into position for bonding to the nextsubstrate. Like the process described above with respect to the 2 to 3micron thick laminate material, the left-over carrier web from thisapproach also becomes scrap which must be thrown away.

An approach is needed which allows high volumes of laminated substratesto be fabricated without generating so much waste.

SUMMARY OF THE INVENTION

The present invention provides methods and apparatus for makinglaminated substrates, such as laminated cards, in which substantially nolaminate material is wasted. Preferred embodiments of the presentinvention use a supply roll of lamina from which successive sheets oflaminate are cut. Advantageously, no carrier web is required, i.e. thesupply of lamina is webless, and no scrap laminate material is generatedexcept for the couple of inches or less of lamina material remaining atthe end of a supply roll when the supply runs out.

The present invention is also quite versatile. Many varieties of cardsubstrates and lamina material of varying type, nature, thickness, size,etc., can be effectively laminated together using the present invention.The present invention can also be set up for fully automatic operationor for hand-fed operation, as desired.

As still another advantage, the present invention allows laminate sheetsto be accurately, reliably, and repeatedly placed in proper registrationon corresponding substrates without any need for registration marks.Whereas prior art approaches require placement of registration marks inscrap areas of laminate materials in order to achieve properregistration, the present invention requires none, and indeed could notuse such marks anyway, because the present invention has no scrap. Asnoted above, substantially all of the laminate material used in themethod and apparatus of the present invention is used.

In one aspect, the advantages of the present invention are provided byan apparatus suitable for making a plurality of laminated substrates byapplying a plurality of laminate sheets to corresponding plurality ofsubstrates. The apparatus includes a lamina supply member capable ofholding a supply of lamina from which successive sheets of lamina can becut. A cutter is disposed in the apparatus such that the cutter iscapable of cutting through the lamina to provide said successive sheetsof laminate. A heater is provided for bonding each successive sheet oflaminate to a corresponding substrate whereby the correspondinglaminated substrate is formed.

Another aspect of the present invention concerns a process for making aplurality of laminated substrates. According to this aspect of thepresent invention, a supply of lamina is provided from which asuccessive plurality of laminate sheets are cut. The supply of lamina ischaracterized by a current leading edge. The supply of lamina is cutthrough along a cutting line at a predetermined distance from thecurrent leading edge of the lamina. This provides a first sheet oflaminate having a trailing edge at the cutting line. Cutting alsoprovides the lamina supply with a successive leading edge at the cuttingline. There is substantially no wasted lamina material between thetrailing edge of the laminate sheet and the successive leading edge ofthe lamina. The laminate sheet is then bonded to a correspondingsubstrate. The steps of cutting the lamina along a cutting line andbonding the resultant lamina sheet to a corresponding substrate arerepeated a plurality of times to yield the plurality of laminatedsubstrates.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of this invention,and the manner of attaining them, will become more apparent and theinvention will be better understood by reference to the followingdescription of the invention taken in conjunction with the accompanyingfigures, wherein:

FIG. 1 is a plan view showing a lamina processing assembly of thepresent invention;

FIG. 2 is a gear drive train of the present invention corresponding tothe lamina processing assembly of FIG. 1;

FIG. 3a is a schematic perspective view of a supply roll of laminasuitable for use in the practice of the present invention;

FIG. 3b is a schematic perspective view of the supply roll of lamina ofFIG. 3a after a laminate sheet has been cut from the roll;

FIG. 4a side view of a pair of motor driven scissors used in theassembly of FIG. 1 with some parts shown in cross section;

FIG. 4b is a top view of the scissors of FIG. 4a with some parts removedfor clarity;

FIG. 5 is an end view of the scissors of FIG. 4a with parts removed tomore clearly show the blade cam whose rotation opens and closes thescissors;

FIG. 6 is a perspective view showing the portion of the apparatus nearthe substrate entry zone of the lamina processing assembly of FIG. 1;

FIG. 7 is a side view of the heating apparatus used in the assembly ofFIG. 1 with some parts shown in cross-section;

FIG. 8 is an end view of a portion of the heating apparatus of FIG. 7;and

FIG. 9 is a perspective view of a laminated substrate prepared inaccordance with the present invention.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplification set out hereinillustrates one preferred embodiment of the invention, in one form, andsuch exemplification is not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

The various aspects of the present invention will now be described withreference to the particular laminating apparatus 10 shown in thefigures. However, the description disclosed below are not intended to beexhaustive or to limit the invention to the precise forms disclosed inthe following detailed description.

The apparatus 10 comprises a support structure containing a fronthousing wall 11 (part of which is shown only in FIGS. 6 and 7) and arear housing wall which for purposes of clarity is not shown in thedrawings. Middle housing wall 12 is disposed between the front housingwall and the rear housing wall and divides apparatus 10 into two mainchambers. First chamber 13 houses gear and sprocket drive train,generally designated 14 in FIG. 2. The second chamber 15 houses thelamina processing assembly, generally designated 16 in FIG. 1.

The lamina processing assembly 16 includes a lamina supply member 20 onwhich a supply roll of heat bondable lamina 18 is rotatably stored. Awide variety of heat bondable lamina materials may be used in thepractice of the present invention. Representative examples of suitablelamina material include "TBSN" lamina material available fromTransilWrap and "H12-V" lamina material available from the MinnesotaMining and Manufacturing Company (3M).

A lamina supply path 22 extends from lamina supply member 20 toconvergence zone 24. Optionally, a sensor (not shown) of any suitabletype may be disposed on lamina supply path 22 proximal to supply member20 in order to detect when the supply of lamina 18 runs out. Laminasupply path 22 passes between a first set of corresponding pinch rollers26 and 28 and a second set of corresponding pinch rollers 30 and 32.First set of pinch rollers 26 and 28 are disposed on the lamina supplypath 22 at a position which is upstream relative to a cutter which isgenerally designated 42. Second set of pinch rollers 30 and 32 arelocated on the lamina supply path 22 at a position which is downstreamrelative to the cutter 42.

First set of pinch rollers 26 and 28 are rotatably driven byclutch-driven gear and sprocket assembly 34 and idler gear 36,respectively. In a similar fashion, second set of pinch rollers 30 and32 are driven by clutch-driven gear and sprocket assembly 38 and idlergear 40, respectively. The rotation of the gear and sprocket assemblies34 and 38 and idler gears 36 and 40 causes pinch rollers 26, 30, 28 and32 to correspondingly rotate. Rotation of these rollers, in turn, causestransport of lamina 18 along lamina supply path 22. Desirably, wireguides (not shown for purpose of clarity) may be disposed along the topand bottom of the lamina supply path 22 to help guide lamina 18.

In the embodiment shown in the Figures, cutter 42 is a pair ofmotor-driven scissors. Referring now to FIGS. 1, 3a and 3b inparticular, cutter/scissors 42 is disposed on the lamina supply path 22for cutting the supply of lamina 18 along cutting line 44 at apredetermined distance d, from leading edge 46 of lamina 18. Cutting oflamina 18 along cutting line 44 provides heat bondable laminate sheet 48having the same leading edge 46, but a newly provided trailing edge 50at the cutting line 44. Cutting of lamina 18 along cutting line 44 alsoprovides the supply roll of lamina 19 with a successive leading edge 52.The remaining portion of lamina 18 may then be cut along successivecutting line 55 to provide the next sheet of laminate corresponding tothe portion of lamina 18 between successive leading edge 52 andsuccessive cutting line 55. Additional sheets of laminate can besuccessively cut from the remaining portions of lamina 18 in a similarfashion until the supply of lamina runs out.

Advantageously, in the practice of the present invention, a plurality oflaminate sheets can be cut from lamina supply 18 with substantially nowaste between the trailing edge of each cut sheet and the successiveleading edge of the next laminate sheet. As a result, except for thecouple of inches or less of material remaining at the end of a roll, thepresent invention generates no wasted lamina, in sharp contrast to theprior art approaches which waste significant amounts of material.

Referring in particular now to FIGS. 1, 2, 4a, 4b, and 5, scissors 42 issecured in apparatus 10 upon mounting block 56. Scissors 42 includes atop cutting blade 59 provided on a fixed top arm 60. Fixed top arm 60,in turn, is mounted to mounting block 56. A bottom cutting blade 61 isprovided on a pivoting bottom arm 62. Pivoting bottom arm 62 includes apivoting arm portion 63 which is pivotably coupled to blade pivot 64.Bottom cutting blade 61 can thus pivot about the blade pivot 64 from anopen position as shown in the Figures to a closed position at which thebottom cutting blade 61 cuttingly engages top cutting blade 59. Whenbottom cutting blade 61 is in the open position, lamina supply path 22passes between top cutting blade 59 and bottom cutting blade 61. Whenthe supply of lamina 18 is conveyed along lamina supply path 22 betweenblades 60 and 62, bottom cutting blade 61 closes and then opens to cutthe lamina with a scissor type action.

Advantageously, lamina spring 65 is disposed on mounting block 56 tohelp bias the lamina 18 downward away from the fixed cutting blade 59 asthe leading edge of the lamina 18 is guided through scissors 42. In theabsence of lamina spring 65, the leading edge of lamina 18 may tend tojam against the upstream side of the top cutting blade 59 and/or thefixed top arm 60. Lamina spring 65 is desirably fabricated from aresiliently flexible material such as a metal, metal alloy,thermoplastic or thermoset polymer, and the like. Specific examples ofsuitable materials would include polycarbonate, polyurethane, polyester,copper, bronze, stainless steel, and aluminum or an aluminum alloy.

Fingers 66 project backwards from mounting block 56 and fit intocorresponding grooves (not shown) in roller 26. Fingers 66 help preventlamina 18 from wrapping upward around roller 26 as the leading edge oflamina 18 is guided past roller 26.

In the embodiment shown, scissors 42 is motor-driven. To accomplishthis, clutch-controlled sprocket assembly 72 rotatably drives blade camshaft 70 which, in turn, rotatably drives blade cam 68. Blade cam shaft70 is rotatably journalled upon bearings 86 and 87 which are provided inapertures of auxiliary housing wall 58 and middle housing wall 12. Bladecam 68 includes ball track 74 for retaining cam follower 76. Finger 78,provided at the end of pivoting bottom arm 62, couples pivoting bottomarm 62 to cam follower 76. Rotatable blade cam 68 is eccentricallymounted on blade camshaft 70 such that rotation of blade cam 68 causesthe pivoting bottom cutting blade 62 to pivotally open and close aboutblade pivot 64. As seen best in FIG. 1, scissors 42 is oriented suchthat the cutting action of the scissors is substantially perpendicularto the lamina supply path 22.

Generally, one revolution of blade cam 68 closes and then opens bottomcutting blade 61. To control this cutting action so that scissors 42cuts each laminate sheet only once, shaft 70 is provided with shaftrotary location pin 83. Once during each revolution of shaft 70, pin 83contacts shaft location switch 82. Thus, at the beginning of a cuttingstroke, pin 83 may be positioned so that pin 83 is in contact, or justpast the point of contact if desired, with switch 83. Clutch controlledsprocket 72 is engaged to rotate shaft 70. At the end of one shaftrevolution, scissors 42 will have closed and opened to cut a laminatesheet from lamina 18. Pin 83 contacts switch 82 again after onerevolution of shaft 70 as well, and sprocket 72 is then disengaged.

In those embodiments in which the fixed cutting blade is provided on theupstream side of scissors 42 relative to the pivoting cutting blade,successive leading edges of lamina 18 may tend to stick to fixed cuttingblade 59 and/or fixed top arm 60 after lamina 18 has been cut. As aresult, it then becomes difficult to convey such successive leading edgepast scissors 42. Therefore, according to the embodiment of the presentinvention shown in the Figures, the pivoting cutting blade 61 isdisposed on the lamina supply path on the upstream side of scissors 42relative to fixed cutting blade 59. Advantageously, successive leadingedges of cut lamina 18 do not tend to stick to the scissors 42 aftercutting when the pivoting blade 61 is located on the upstream side ofscissors 42, because the opening action of the pivoting blade 61 tendsto release the successive leading edges.

Referring now to FIG. 1 in particular, apparatus 10 includes sensor 88provided on mounting block 89 along supply path 22 between scissors 42and convergence zone 24 in order to detect when a predeterminedreference on lamina 18 is at a predetermined distance from the cuttingline of scissors 42. Such a reference may be any suitable feature oflamina 18 which can be detected by the sensor. Examples of such featuresinclude the leading edge of the lamina 18 as well as markings, such asauthentication images, provided on the surface of lamina 18. In theparticular embodiment shown in FIG. 1, sensor 88 is disposed at apredetermined distance from the cutting line of scissors 42 to detecteach successive leading edge of the supply of lamina 18 as lamina 18 isconveyed along path 22. When sensor 88 detects each such leading edge,lamina 18 being conveyed is stopped, and scissors 42 is actuated to cutlamina 18. As this process is repeated, all of the resultant laminatedsheets will have been cut to a substantially identical lengthcorresponding to the distance between sensor 88 and the cutting line ofscissors 42. Advantageously, this approach is extremely accurate,reliable, and repeatable.

For example, laminate sheets are used to laminate many kinds of ISOStandard CR-80 type cards. All such cards, within specificationtolerances, are characterized by a width of 2-1/8 inches (5.40 cm) and alength of 3-3/8 inches (8.57 cm). By providing a supply of lamina havinga width of 2 inches (5.08 cm), and by positioning sensor 88 at apredetermined distance of 3-1/4 inches (8.25 cm) from the cutting lineof scissors 42, a plurality of sheets suitable for laminating such cardscan be easily provided using apparatus 10 of the present invention.

In other applications, lamina supply 18 may bear a plurality ofauthentication images, such as holographic images or the like, whichmust be precisely positioned on each corresponding substrate. Forexample, drivers licenses of some states and countries include aholographic authentication image precisely positioned over portions ofthe photographic image and textual information included on suchlicenses. To use apparatus 10 to make a plurality of laminated sheetssuitable for laminating such substrates, alternative embodiments of theinvention may include sensor 90 disposed at a position on lamina supplypath 22 suitable for detecting when the authentication reference, ratherthan the leading edge, of lamina 18 is at a predetermined distance fromthe cutting line of scissors 42. When sensor 90 detects each suchauthentication image, scissors 42 may then be actuated to cut the lamina18. As this process is repeated, all of the resultant laminated sheetswill have been cut to a substantially identical length in which theauthentication image is precisely positioned on each such sheet. Sensor90 may be mounted on mounting block 91.

In the practice of the present invention, sensors 88 and 90 used inapparatus 10 may be any type of sensor known in the art which would besuitable for detecting the predefined reference of the lamina. Oneexample of a type of sensor found to be suitable in the practice of thepresent invention for this purpose is a standard reflective type LEDsensor. Such sensors are reliable and accurate. Further, as known in theart, the reliability and accuracy of such sensors can be even furtherimproved by placing a dull, black, nonreflective plate (not shown), oranother nonreflective type of member, in opposition to such sensors inorder reduce the tendency of such sensors to generate false detectionsignals.

Referring now to FIGS. 1, 2 and 6 in particular, apparatus 10 includes asubstrate supply path 92 extending from substrate entry zone 94 toconvergence zone 24. A substrate guiding device, generally designated96, is provided on substrate supply path 92 near substrate entry zone94. Substrate guiding device 96 includes bevelled entry blocks 98 and 99provided on each side of the substrate supply path 92. As seen best inFIG. 6, bevelled entry block 98 is mounted on front housing wall 11, andbevelled entry block 99 is mounted on middle housing wall 12. Abovebevelled entry blocks 98 and 99, deflection plate 114 is pivotablydisposed between auxiliary plates 116 and 117 on axle 118. Deflectionplate 114 biases the substrates downward onto substrate supply path 92.A plurality of structural members, such as structural members 120, 121,122 and 123, are provided in order to impart strength and rigidity toapparatus 10.

First conveyor roller 102 is rotatably supported between bevelled entryblocks 98 and 99. Further along the substrate supply path 92, path 92passes between pinch roller 108 and second conveyor roller 104. A pairof endless loop drivers 106 and 107 are mounted around first conveyorroller 102 and second conveyor roller 104. Pinch roller 108 and secondconveyor roller 104 are rotatably driven by clutch-controlled gear andsprocket assembly 110 and idler gear 112, respectively. Rotation ofsecond conveyor roller 104, in turn, causes rotation of endless loopdrivers 106 and 107 about first conveyor roller 102 and second conveyorroller 104. Such rotation of endless loop drivers 106 and 107 causestransport of a substrate along that portion of substrate supply path 92corresponding to endless loop drivers 106 and 107.

Support member 124 is provided for supporting the substrate alonganother portion of path 92 after the substrate is conveyed past pinchroller 108 and second conveyor roller 104. Support member 124 has a flatupper surface 126 providing a pathway which is slidably engaged by thesubstrate as the substrate is conveyed across support member 124.Support member 124 further includes a pair of sidewall members, one ofwhich is shown as sidewall 128, to help constrain the substrate inposition on upper surface 126. Upper surface 126 includes an entry bevel130, and the sidewall members include entry bevels such as bevel 132, inorder to ease entry of the substrate onto support member 124.

Sensor 134 is provided on the substrate supply path 92 and is mounted inposition by fastening sensor flange 136 to the underside surface 137 ofsupport member 124 with a suitable fastener, such as screw 138. Sensor134 detects when a reference on the substrate is at a predetermineddistance from the convergence zone 24. As was the case with lamina 18,the substrate reference may be any suitable feature of the substratewhich can be detected by sensor 134. Examples of such features includethe leading edge of the substrate as well as any markings, such asimages or textual information, which may be provided on the substrate.

In the particular embodiment shown in the figures, the position ofsensor 134 is coordinated with the position of sensor 88 so that thesubstrate and the laminate sheet, after the sheet has been cut fromlamina 18, arrive at convergence zone 24 in a manner which allows thesubstrate and the laminate sheet to be brought together in properregistration. For example, the cut sheet of laminate and the substratedesirably arrive at the convergence zone 24 at substantially the sametime while being conveyed at substantially the same speed along theirrespective paths. In such embodiments, the distance between convergencezone 24 and sensor 134 is substantially the same as the distance betweenconvergence zone 24 and sensor 88.

In the practice of the present invention, sensor 134 may be any sensorknown in the art which would be suitable for detecting the predefinedreference of the substrate. As was the case with sensors 88 and 90, oneexample of a type of sensor found to be suitable in the practice of thepresent invention is a standard reflective type LED sensor. As was alsothe case with sensors 88 and 90, the performance of such a sensor can beimproved by placing a dull, nonreflective, black plate (not shown), oranother non-reflective type of member, in opposition to said sensor inorder to reduce the tendency of such sensor to generate false detectionsignals. Due to the positioning of sensors 88 and 134, a single platemay be disposed between the two sensors in order to reduce such falsedetection incidents.

In convergence zone 24, the laminate sheet and substrate are registrablybrought into contact to provide a sheet-bearing substrate. Convergencezone 24, as shown, comprises a pair of pinch rollers 140 and 142 whichare rotatably driven by idler gear 146 and clutch-driven gear andsprocket assembly 144, respectively. Lamina supply path 22 and substratesupply path 92 converge between pinch rollers 140 and 142 at convergencepoint 143 to form processing path 148, which extends from such point ofconvergence 143 to exit zone 150.

Heating apparatus 152 is disposed on processing path 148 for bonding thelaminate sheet to a corresponding substrate. Heating apparatus 152includes heated roller assembly 154 and corresponding pinch roller 156.Heated roller assembly 154 and pinch roller 156 are disposed onprocessing path 148 such that the laminate-bearing substrate is conveyedbetween heated roller assembly 154 and pinch roller 156 as the laminatebearing substrate is conveyed along the processing path. Pinch roller156 is rotatably mounted on adjustment plate 162. Movement of adjustmentplate 162 allows the distance between pinch roller 156 and heated rollerassembly 154 to be changed in order to accommodate different thicknessof substrates and laminates. Heated roller assembly 154 and pinch roller156 are rotatably driven by gear 158 and gear 160, respectively.Together, heated roller assembly 154 and pinch roller press the laminatesheet and the substrate together as the heater applies heat for bonding.

As shown best in FIGS. 7 and 8, heated roller assembly 154 includes anon-rotatable heater core 164 having a heated portion 166. Rotatableouter shell 168 is disposed on non-rotatable heater core 164 such thatthe non-rotatable heater core 164 heats rotatable outer shell 168.Rotatable outer shell 168, in turn, heatably bonds the laminate sheet tothe substrate. Rotatable outer shell 168 is coupled to non-rotatableheater core 164 by any suitable bearing means which allows rotatableouter shell 168 to rotate freely about the non-rotatable heater core164. As shown in the embodiment in FIG. 7, rotatable outer shell 168 iscoupled to non-rotatable heater core 164 by inner pair of bearings 170and 171 and outer pair of bearings including bearing 172 and the hub ofgear 158 which serves as the other outer bearing. Gear 158 couples theheated roller assembly 154 to pinch roller 156.

In one mode of practicing the present invention, inner bearings 170 and171 are non-rotatably coupled to the non-rotatable heater core 164.Additionally, outer bearing 172 and the hub of gear 158 arenon-rotatably coupled to rotatable outer shell 168. Outer bearing 172and the hub of gear 158, however, are fully rotatable about innerbearings 170 and 171. In order to reduce friction between the two setsof bearings, it is desirable that at least one set of such bearingscomprises a self lubricating resin which is preferablypolytetrafluorethylene. Polytetrafluorethylene is more commonly referredto by its trade designation "Teflon". For example, inner bearing 170 andthe hub of gear 158 may be fabricated from Teflon brand resin and outerbearing 172 and gear 158 may be fabricated from stainless steel.

Heated roller assembly 154 is mounted between middle housing wall 12 andfront housing wall 11. Middle housing wall 12 and front housing wall 11desirably include apertures for receiving corresponding ends ofnon-rotatable heater core 164. Flange 174 is used to secure heatedroller assembly 154 to the middle housing wall 12 using any suitablefastener, such as screws 176.

Pinch roller 156 includes a roller body 177 and an axle 178. Axle 178 isrotatably received in corresponding apertures provided in middle housingwall 12 and front housing wall 11. Pinch roller 156 is secured in placeby auxiliary plates 186 and 187 which are fastened to middle housingwall 12 and front housing wall 11 using any suitable fastener, such asscrews 188. Pinch roller 156 is rotatably driven by gear 160. Gear 180of pinch roller 156, in turn, rotatably drives gear 158 of heated rollerassembly 154.

Energy for heating heated portion 166 of non-rotatable heater core 164is provided to heated roller assembly 154 through heater wires 190.Thermocouple wires 192 are used to monitor the temperature ofnon-rotatable heater core 164. In order to maintain the non-rotatableheater core 164 at a desired temperature, the energy supply to heaterwires 190 can be increased or decreased, as needed.

The process of using heat to bond the laminate sheet to the substratecan cause the resultant laminated substrate to bend, or "cargo" as suchbending is sometimes called. Depending upon the materials used tofabricate the laminate sheet and the substrate, the face of thelaminated substrate bearing the laminate sheet can be characterized by aconvex or concave bend. It is desirable, therefore, to apply a reversebend to the laminated substrate in order to remove such convex orconcave bend.

Accordingly, as seen best in FIGS. 1 and 2, card straightener 194 isprovided on processing path 148 for applying a reverse bend to thelaminated substrate after the laminated substrate leaves heatingapparatus 152. In the embodiments of the present invention as shown inthe Figures, card straightener 194 is an assembly comprising a firstpinch roller 196 having a center of rotation 198 and a second pinchroller 200 having a center of rotation 202. Pinch rollers 196 and 200are rotatably mounted on adjustment plate 204 and are disposed onprocessing path 148 such that processing path 148 passes between rollers196 and 200. A line extending from the center of rotation 198 to thecenter of rotation 202 defines a main axis of the card straightener 194.Adjustment plate 204 is pivotable about a pivot point so that the mainaxis of the card straightener 194 can be pivoted as well. Preferably,center of rotation 202 or 198, and more preferably center of rotation202, serves as the pivot point for adjustment plate 204. Pinch rollers196 and 200 are rotatably driven by gears 206 and 208, respectively.

Advantageously, because the main axis of card straightener is pivotable,card straightener 194 can be adjusted to provide a reverse convex orconcave bend as desired. For example, in the embodiment in which centerof rotation 202 serves as the pivot point for adjustment plate 204,pivoting of adjustment plate 204 toward the exit zone 150 causes themain axis of the card straightener 194 to pivot toward exit zone 150 aswell. Such an orientation of the axis applies a reverse bend to thelaminated substrate in which the leading edge of the laminated substrateis flexed downward. This is a useful approach for applying a reversebend when the laminated substrate emerges from heating apparatus 142 ina condition in which the laminate sheet bearing side of the laminatedsubstrate has a concave bend. On the other hand, pivoting of theadjustment plate 204 toward the heating apparatus 152 causes the mainaxis to pivot toward heating apparatus 152 as well. Such orientation ofthe main axis applies a reverse bend to the laminated substrate in whichthe leading edge of the laminated substrate is flexed upward by cardstraightener 194. This is a useful approach when the laminated substrateemerges from the heating apparatus 152 in a condition in which thelaminate bearing side of the laminated substrate has a convex bend.

Gear and sprocket drive train 14 will now be more fully described withparticular reference to FIG. 2. Power from a motor (not shown) istransferred to drive train 14 through motor driven gear 210. To ensurethat the various components of the drive train embodiment shown in FIG.2 rotate in the proper direction, motor driven gear 210 rotatescounter-clockwise and is coupled to the remainder of drive train 14through large idler gear 212. Rotation of idler gear 212 rotatablydrives gear 146. Rotational power of gear 146 is subsequentlytransferred to gear 160 and gear 208 through idler gears 214 and 215,respectively. Idler gears 214 and 215 not only transfer power to gears160 and 208, but the use of idler gears 214 and 215 also ensures thatgears 160 and 208 are rotating in the proper direction. Gears 160 and208 rotatably drive gears 158 and 206, respectively.

Gear 146 also transfers rotational power to gear and sprocket assembly144. Gear and sprocket assembly 144 is coupled, in turn, to clutchdriven gear and sprocket assemblies 34, 38, and 110, as well as clutchdriven sprocket 72, by timing belt 216. Clutch driven sprocketassemblies 34, 38, and 110, in turn, rotatably drive corresponding gears36, 40, and 112. Drive train 14 further includes idler gear 218 which isdisposed in drive train 14 in a manner to maintain engagement betweentiming belt 216 and clutch driven gear and sprocket assemblies 34 and38. Adjustable belt tensioning sprocket 220 is also provided and can bemoved to adjust the tension of timing belt 216, as desired.Advantageously, use of timing belt 216 causes gear and sprocketassemblies 34, 38, 110, and 144 all to rotate at substantially the samerotational speed so that the substrate and the laminate sheet areconveyed along their respective paths at substantially the same speed.The scissor sprocket 72 need not rotate at the same speed as suchassemblies, and, in the embodiment shown, sprocket 72 is configured torotate at a quicker speed than such assemblies.

One mode of operation of the apparatus shown in the Figures will now bedescribed. Clutch driven gear and sprocket assemblies 34 and 38 areengaged to cause rotation of rollers 26, 28, 30, and 32. Rotation ofthese rollers causes the transport of lamina 18 along lamina supply path22. When the leading edge of lamina 18 is detected by sensor 88 orsensor 90, as the case may be, clutch driven gear and sprocketassemblies 34 and 38 are disengaged and transport of lamina 18 stops.Scissors 42 is then actuated to cut through lamina 18 along a cuttingline to provide a first cut sheet of heat bondable laminate.

After scissors 42 cuts the lamina 18, clutch driven sprocket and gearassembly 110 is engaged which, in turn, actuates rollers 108, 104, and102 to convey a substrate along the substrate supply path 92. Engagingsprocket and gear assembly 110 only after the lamina 18 is cut helpsmake sure that a substrate is not fed into the apparatus 10 too soon.The substrate enters apparatus 10 through substrate entry zone 94.Substrate may be fed into apparatus 10 in any desired manner. Forexample, the substrate may be hand fed into apparatus 10 oralternatively, may be automatically fed into apparatus 10 directly froma suitable device, such as a printer. As the substrate enters apparatus10, deflection plate 114 biases the substrate against endless loopdrivers 106 and 107. To convey the substrate along substrate supply path92, clutch driven gear and sprocket assembly 110 is engaged to rotatablydrive pinch roller 108, first conveyor roller 102, second conveyorroller 104, and endless loop drivers 106 and 107.

When the substrate is conveyed far enough along the substrate supplypath 92, sensor 134 will detect the presence of the substrate. When thishappens, clutch driven gear and sprocket assembly 38 is engaged and boththe substrate and the lamina sheet are conveyed between pinch rollers140 and 142 at substantially the same time while being transported atsubstantially the same speed.

Meanwhile, rollers 140, 142, 154, 156, 196 and 200 are rotatably drivenby corresponding components-of gear drive train 14, and rotation ofthese rollers conveys the substrate and laminate along the processingpath 148. As the laminated sheet and the substrate pass between pinchrollers 140 and 142, successive portions of the laminate sheet and thesubstrate are brought into contact. A laminate bearing substrate thenemerges from between pinch rollers 140 and 142 and is next conveyedbetween heated roller assembly 154 and pinch roller 156. As the laminatesheet and the substrate are pressed together, heat from heated roller154 activates the adhesive on the laminate sheet in order to bond thelaminate sheet to the substrate. Given the characteristics of particularlamina 18 and substrate used, the laminated products produced may tendto be characterized either by a convex or concave bend. If this happens,card straightener 194 may be adjusted to apply an appropriate reversebend to the laminated product before the laminated product leavesapparatus 10 through exit zone 150. Subsequent laminated products areformed from lamina 18 and additional substrates by repeating theseoperations.

Any conventional control mechanism can be used in the practice of thepresent invention to respond to sensor signals, actuate the scissors,and engage and disengage the clutch-controlled elements of the gear andsprocket drive-train 14. As one example, apparatus may include amicroprocessor which controls such functions. As an additional option,apparatus 10 may include convenience features which convey informationabout the apparatus 10 to a user. For example, apparatus 10 may beprovided with lights or instruments which tell the user information suchas the status of the lamina supply, the status of the clutch-controlledelements, heater temperature, orientation of the card straightener axis,number of laminate sheets cut by the scissors 42, and the like.

FIG. 9 shows a laminated substrate 300 prepared in accordance with thepresent invention. Laminated substrate 300 includes card-shapedsubstrate 301 having face 302. Substrate 301 may be made from a varietyof materials such as, for example, paper, cardboard, plastic, metal, orthe like. Face 302 may include information such as photographs, othergraphics, text, data, or the like. Laminate sheet 304 is bonded to face302. Optionally, the bottom face (not shown) of substrate 301 may alsoinclude information and have a second laminate sheet bonded to it aswell. Corners 306 are angular, not rounded, and are most typicallysubstantially square. Square corners result when scissors 42 of FIG. 1is used to cut lamina 18 along a cutting line which is substantiallyperpendicular to the sides of lamina 18. Advantageously, laminate sheet304 is slightly narrower and slightly shorter than the face 302 in orderto ease registration of the laminate sheet 304 onto face 302. Forexample, use of a laminate sheet 304 which is 1/8" (0.32 cm) shorter and1/8" (0.32 cm) narrower than substrate 301 has been found to be suitablein the practice of the present invention.

The characteristics of laminated substrate 300 are distinguishable overlaminated substrates made using the prior art techniques describedabove. For example, when using the "decal" approach, the entire face 302is covered by laminate material. When using the "die-cut" approach, thelaminate sheet corners have been rounded, not square.

While this invention has been described as having a preferred design,the present invention can be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the invention using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. A process of making a plurality of laminatedcards, comprising the steps of:(a) providing a webless supply of heatbondable, transparent lamina from which a successive plurality oflaminate sheets is cut, wherein said lamina has a current leading edge;(b) cutting through the line along a cutting line at a predetermineddistance from a reference of the lamina to provide a first sheet oflaminate, wherein said cutting provides the laminate sheet with atrailing edge at the cutting line and wherein said cutting provides thelamina supply with a successive leading edge at the cutting line, andwherein there is no wasted lamina between the trailing edge of thelaminate sheet and the successive leading edge of the lamina; (c)bringing the laminate sheet and a first card together into registrablecontact to substantially completely cover one face of the card; (d) heatbonding the laminate sheet to the first card; and (e) following steps(b), (c) and (d) a plurality of times to yield said plurality oflaminated cards.
 2. The method of claim 1 wherein the step of cuttingthrough a lamina comprises cutting the lamina with a motor driven pairof scissors.
 3. The method of claim 2 wherein:the scissors comprises afixed cutting blade and a pivoting cutting blade being pivotable about ablade pivot from an open position to a closed position; at the openposition, the lamina supply is capable of being conveyed between thefixed cutting blade and the pivoting cutting blade; and at the closedposition, said pivoting cutting blade cuttingly engages the fixedcutting blade.
 4. The method of claim 3 wherein the pivoting cuttingblade is disposed upstream relative to the fixed cutting blade.
 5. Themethod of claim 3 wherein the cutter further comprises a rotatable bladecam shaft and a rotatable blade cam eccentrically mounted on the bladecam shaft, wherein the blade cam is coupled to the pivoting cuttingblade, such that rotation of the blade cam causes the pivoting blade topivotably open and close about the blade pivot.
 6. The method of claim 1wherein the bonding step comprises bonding the entire cut sheet oflaminate to the card such that no portion of the cut sheet compriseswaste material which is not bonded to the card.
 7. A process of making alaminated substrate, comprising te steps of:(a) providing a weblesssupply of heat bondable, transparent from which successive sheets oflaminate are cut, wherein the lamina supply has a leading edge; (b)conveying the lamina along a lamina supply path until a sensor detects areference on the lamina; (c) stopping the conveyance of the lamina alongthe supply path in response to detecting the reference on the lamina;(d) after stopping the lamina, cutting through the lamina along thecutting line at a predetermined distance from the reference of thelamina in order to provide a laminate sheet; (e) providing a substratehaving a leading edge; (f) bringing the laminate sheet and the substratetogether into registrable contact to substantially completely cover oneface of the substrate; and (g) heat bonding the laminate sheet to thesubstrate.
 8. The method of claim 7, wherein the step of cutting throughthe lamina comprises cutting the lamina with a motor driven pair ofscissors.
 9. The method of claim 8 wherein:the scissors comprises afixed cutting blade and a pivoting cutting blade being pivotable about ablade pivot from an open position to a closed position; at the openposition, the lamina supply is capable of being conveyed between thefixed cutting blade and the pivoting cutting blade; and at the closedposition, said pivoting cutting blade cuttingly engages the fixedcutting blade.
 10. The method of claim 9, wherein the pivoting cuttingblade is disposed upstream relative to the fixed cutting blade.
 11. Themethod of claim 9, wherein, the cutter further comprises a rotatableblade cam shaft and a rotatable blade cam eccentrically mounted on theblade cam shaft, and wherein the blade cam is coupled to the pivotingcutting blade such that rotation of the blade cam causes the pivotingblade to pivotably open and close about the blade pivot.
 12. The methodof claim 7, wherein the bonding step comprises bonding the entire cutsheet of laminate to the substrate such that no portion of the cut sheetcomprises waste material which is not bonded to the substrate.